Method for producing a heat transfer medium and device

ABSTRACT

A method for preparing a superconducting heat transfer medium having three basic layers, the method having the steps of preparing a first layer mixture, applying the first layer mixture to a surface of a substrate so as to form a first layer, preparing a second layer mixture, applying the second layer mixture to the substrate over the first layer so as to form a second layer on top of the first layer, preparing a third layer powder, and exposing the second layer to the third layer powder so as to form a third layer on top of the second layer, thus forming the three layer superconducting heat transfer medium.

RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 09/437,659, filed on Nov. 10, 1999, now abandoned,which is a divisional of U.S. patent application Ser. No. 08/957,148filed on Oct. 24, 1997 and which issued as U.S. Pat. No. 6,132,823 onOct. 17, 2000, which in turn is based and claims priority on U.S.provisional patent application No. 60/029,266 filed on Oct. 25, 1996 andU.S. provisional patent application No. 60/036,043 filed on Jan. 27,1997.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates generally to the field of heat transfer.More particularly, the present invention relates to a method forproducing a heat transfer medium that is disposed within a conduit torapidly and efficiently transfer heat.

2. Background Art

Efficiently transporting heat from one location to another always hasbeen a problem. Some applications, such as keeping a semiconductor chipcool, require rapid transfer and removal of heat, while otherapplications, such as disbursing heat from a furnace, require rapidtransfer and retention of heat. Whether removing or retaining heat, theheat transfer conductivity of the material utilized limits theefficiency of the heat transfer. Further, when heat retention isdesired, heat losses to the environment further reduce the efficiency ofthe heat transfer.

For example, it is well known to utilize a heat pipe for heat transfer.The heat pipe operates on the principle of transferring heat throughmass transfer of a fluid carrier contained therein and phase change ofthe carrier from the liquid state to the vapor state within a closedcircuit pipe. Heat is absorbed at one end of the pipe by vaporization ofthe carrier and released at the other end by condensation of the carriervapor. Although the heat pipe improves thermal transfer efficiency ascompared to solid metal rods, the heat pipe requires the circulatoryflow of the liquid/vapor carrier and is limited by the associationtemperatures of vaporization and condensation of the carrier. As aresult, the heat pipe's axial heat conductive speed is further limitedby the amount of latent heat of liquid vaporization and on the speed ofcircular transformation between liquid and vapor states. Further, theheat pipe is conventional in nature and suffers from thermal losses,thereby reducing the thermal efficiency.

An improvement over the heat pipe, which is particularly useful withnuclear reactors, is described by Kurzweg in U.S. Pat. No. 4,590,993 fora Heat Transfer Device For The Transport Of Large Conduction FluxWithout Net Mass Transfer. This device has a pair of fluid reservoirsfor positioning at respective locations of differing temperaturesbetween which it is desired to transfer heat. A plurality of ductshaving walls of a material that conducts heat connects the fluidreservoirs. Heat transfer fluid, preferably a liquid metal such asmercury, liquid lithium or liquid sodium, fills the reservoirs andducts. A piston or a diaphragm within one of the reservoirs createsoscillatory axial movement of the liquid metal so that the extent offluid movement is less than the duct length. This movement functions toalternately displace fluid within the one reservoir such that the liquidmetal is caused to move axially in one direction through the ducts, andthen to in effect draw heat transfer fluid back into the one reservoirsuch that heat transfer fluid moves in the opposite direction within theducts. Thus, within the ducts, fluid oscillates in alternate axialdirections at a predetermined frequency and with a predetermined tidaldisplacement or amplitude. With this arrangement, large quantities ofheat are transported axially along the ducts from the hotter reservoirand transferred into the walls of the ducts, provided the fluid isoscillated at sufficiently high frequency and with a sufficiently largetidal displacement. As the fluid oscillates in the return cycle to thehotter reservoir, cooler fluid from the opposite reservoir is pulledinto the ducts and the heat is then transferred from the walls into thecooler fluid. Upon the subsequent oscillations, heat is transferred tothe opposite reservoir from the hotter reservoir. However, as with theheat pipe, this device is limited in efficiency by the heat transferconductivity of the materials comprising the reservoirs and ducts and byheat losses to the atmosphere.

It is known to utilize radiators and heat sinks to remove excess heatgenerated in mechanical or electrical operations. Typically, a heattransferring fluid being circulated through a heat-generating sourceabsorbs some of the heat produced by the source. The fluid then ispassed through tubes having heat exchange fins to absorb and radiatesome of the heat carried by the fluid. Once cooled, the fluid isreturned back to the heat-generating source. Commonly, a fan ispositioned to blow air over the fins so that energy from the heat sinkradiates into the large volume of air passing over the fins. With thistype of device, the efficiency of the heat transfer is again limited bythe heat transfer conductivity of the materials comprising the radiatoror the heat sink.

Dickinson in U.S. Pat. No. 5,542,471 describes a Heat Transfer ElementHaving The Thermally Conductive Fibers that eliminates the need for heattransferring fluids. This device has longitudinally thermally conductivefibers extended between two substances that heat is to be transferredbetween in order to maximize heat transfer. The fibers are comprised ofgraphite fibers in an epoxy resin matrix, graphite fibers cured from anorganic matrix composite having graphite fibers in an organic resinmatrix, graphite fibers in an aluminum matrix, graphite fibers in acopper matrix, or a ceramic matrix composite.

In my People's Republic of China Patent Number 89108521.1, I disclosedan Inorganic Medium Thermal Conductive Device. This heat-conductingdevice greatly improved the heat conductive abilities of materials overtheir conventional state. Experimentation has shown this device capableof transferring heat along a sealed metal shell having a partial vacuumtherein at a rate of 5 meters per second. On the internal wall of theshell is a coating applied in three steps having a total optimumthickness of 0.012 to 0.013 millimeters. Of the total weight of thecoating, strontium comprises 1.25%, beryllium comprises 1.38% and sodiumcomprises 1.95%. This heat conducting device does not contain a heatgenerating powder and does not transfer heat nor prevent heat losses tothe atmosphere in a superconductive manner as the present invention.

BRIEF SUMMARY OF THE INVENTION

It is generally accepted that when two substances having differenttemperatures are brought together, the temperature of the warmersubstance decreases and the temperature of the cooler substanceincreases. As the heat travels along a heat-conducting conduit from awarm end to a cool end, available heat is lost due to the heatconducting capacity of the conduit material, the process of warming thecooler portions of the conduit and thermal losses to the atmosphere. Inaccordance with the present invention and these contemplated problemsthat have and continue to exist in this field, one objective of thisinvention is to provide a method for producing a heat transfer mediumthat is environmentally sound, rapidly conducts heat and preserves heatin a highly efficient manner. Further, the present invention does notrequire a tightly controlled process environment to produce a heattransfer medium.

Another object of this invention is to provide a method for producing adevice that conducts heat with a heat preservation efficiencyapproaching 100 percent.

Also, another object of this invention is to provide a method for thedenaturation of rhodium and radium carbonate.

Yet another objective of this invention is to provide a method forproducing a heat transfer device that is capable of transferring heatfrom a heat source from one point to another.

Still yet another object of this invention is to provide a method forproducing a heat sink utilizing the heat transfer medium that rapidlyand efficiently disburses heat from a heat-generating object.

A further objective of this invention is to provide a method forproducing a device that rapidly conducts cold temperatures from one endof the device to the other end.

This invention accomplishes the above and other objectives and overcomesthe disadvantages of the prior art by providing a method for producing aheat transfer medium that results in a heat transfer device that isrelatively inexpensive to prepare, simple in design and application, andeasy to use.

In the present method, the heat transfer medium is applied to asubstrate in three basic layers. The first two layers are prepared frommixtures that are exposed to a surface or wall of the substrate.Initially, the first layer, which primarily comprises variouscombinations of sodium, beryllium, a metal such as magnesium oraluminum, calcium, boron and dichromate radical, is at least partiallyabsorbed into the surface of the substrate to a depth of 0.008 mm to0.012 mm. Subsequently, the second layer, which primarily comprisesvarious combinations of cobalt, manganese, beryllium, strontium,rhodium, copper, ,β-titanium, potassium, boron, calcium, a metal such asmagnesium or aluminum and the dichromate radical, builds on top of thefirst layer and actually forms a film having a thickness of 0.008 mm to0.012 mm over the surface of the substrate. Finally, the third layer isa powder comprising various combinations of rhodium oxide, potassiumdichromate, radium oxide, sodium dichromate, silver dichromate,monocrystalline silicon, beryllium oxide, strontium chromate, boronoxide, β-titanium and a metal dichromate, such as magnesium dichromateor aluminum dichromate, that evenly distributes itself across thesurface. In an illustrative example, the three layers can be applied tothe inner wall of a conduit and then heat polarized to form asuperconducting heat transfer device, or can be applied to a pair ofplates having a small cavity relative to a large surface area to form aheat sink that can immediately disburse heat from a heat source.

It is to be understood that the phraseology and terminology employedherein are for the purpose of description and should not be regarded aslimiting. For example, the term superconducting is used to denote aprocess that is faster and/or more efficient than the currently knownart. As such, those skilled in the art will appreciate that theconception, upon which this disclosure is based, may readily be utilizedas a basis for the designing of other structures, methods, and systemsfor carrying out the several purposes of the present invention. It isimportant, therefore, that the claims be regarded as including suchequivalent constructions insofar as they do not depart from the spiritand scope of the present invention.

Other objects, advantages and capabilities of the invention will becomemore apparent to those of ordinary skill in the art from the followingdescription of the preferred embodiments when taken in conjunction withthe accompanying drawings showing the preferred embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a superconducting heat transfer devicemade in accordance with the present invention.

FIG. 2 is a cross-sectional view of the device of FIG. 1.

FIG. 3 is a perspective view of a plug used with the device in FIG. 1.

FIG. 4 is a perspective view of a heat sink made in accordance with thepresent invention.

FIG. 5 is a side elevation view of the heat sink of FIG. 4.

FIG. 6 is a cross-sectional view of the heat sink of FIG. 4.

FIG. 7 is an example testing apparatus for testing a heat transferdevice made in accordance with the present invention.

FIG. 8 is the data from the results of Test No. 1 on a preferredembodiment of a heat transfer device made in accordance with the presentinvention.

FIG. 9 is the data from the results of Test No. 2 on a preferredembodiment of a heat transfer device made in accordance with the presentinvention.

FIG. 10 is the data from the results of Test No. 3 on a preferredembodiment of a heat transfer device made in accordance with the presentinvention.

FIG. 11 is the data from the results of Test No. 4 on a preferredembodiment of a heat transfer device made in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For a fuller understanding of the nature and desired objects of thisinvention, reference should be made to the following detaileddescription taken in connection with the accompanying drawings.Referring to the drawings wherein like reference numerals designatecorresponding parts throughout the several figures, reference is madefirst to FIGS. 1 and 2. A heat transfer device 2 produced according tothe method of the present invention is shown. Heat transfer device 2comprises a carrier such as conduit 4 containing a heat transfer medium6, which can be placed within a cavity 8 of conduit 4 without regard tothe material comprising conduit 4. The resulting heat transfercapabilities of medium 6 bearing conduit 4 are greatly enhanced relativeto the known art, and are termed superconducting or superconductiveherein. Medium 6 is activated at a temperature of 38° C. and can operateto a maximum temperature of 1730° C. Because medium 6 is capable ofquickly and efficiently transferring heat through conduit 4 from a heatsource (not shown), conduit 4 can be exposed to and operate within anenvironment having a source temperature far in excess of the meltingtemperature of the untreated material comprising conduit 4.

During the initial stages of medium 6 activation, the medium 6 can reactendothermically. As a result, medium 6 can absorb available heat fromthe heat source and thereafter transfer the heat throughout conduit 4.If the cubic area of cavity 8 is small in relation to external surface10 area of conduit 4, as shown in FIGS. 4 through 6, medium 6 absorbsheat to provide a heat sink 12 that removes heat from theheat-generating source. Heat radiation is directly related to thedensity of heat capacity and the rate of heat conduction and thermalconductivity. This, in other words, determines the speed (rate) at whichthe volume (quantity) of heat can be transferred in each unit volume. Ithas been found that the rate at which the heat can be transferred usinga device produced from the disclosed method is greater than the knownart.

If conduit 4, or other carrier such as disclosed below, has a smallcavity in relation to a large external surface 10 area, the carrier ismore capable of distributing heat across the external surface 10. Inapplications where the temperature of the heat-generating source doesnot exceed 38° C., which is the activation temperature of medium 6, theheat is immediately absorbed and dispersed by medium 6. In cases wherethe heat generating source exceeds 38° C., heat sink 12 is still highlyeffective because of the ability of medium 6 to rapidly transfer theheat to heat sink external surface 14 and be efficiently dispersed tothe atmosphere by thermal radiation.

Using the method of the present invention, medium 6 is applied to asubstrate in three basic layers. The first two layers are prepared frommixtures of components, and the mixtures are exposed to the substratesurface, such as an inner conduit surface 16 or an inner heat sinksurface 18. Initially, first layer mixture is at least partiallyabsorbed into inner conduit surface 16 or heat sink surface 18, formingfirst layer 20. Subsequently, second layer mixture builds on top offirst layer 20 and actually forms a film over inner conduit surface 16or heat sink surface 18, forming second layer 22. Finally, third layer24 is a powder that is evenly distributed across inner conduit surface16 or heat sink surface 18. Although reference is made to conduit 4below in the discussion of medium 6, the application of medium 6 withinheat sink 12 is the same.

First layer 20, called an anti-corrosion layer, prevents etching ofinner conduit surface 16. A further function of first layer 20 is toprevent inner conduit surface 16 from producing oxides. For example,ferrous metals can be easily oxidized when exposed to water moleculescontained in the air. The oxidation of inner conduit surface 16 cancause corrosion and also can create a heat resistance. As a result,there is an increased heat load while heat energy is transferred withinconduit 4, thus causing an accumulation of heat energy inside conduit 4.Should this occur, the life span of medium 6 is decreased.

Next, second layer 22, called the active layer, prevents the productionof elemental hydrogen and oxygen, thus restraining oxidation betweenoxygen atoms and the material of conduit 4 (or carrier). Second layer 22conducts heat across inner conduit surface 16 analogously to that ofelectricity being conducted along a wire. Experimentation has found thatheat can be conducted by medium 6 at a rate of 15,000 meters per second.Second layer 22 also assists in accelerating molecular oscillation andfriction associated with third layer 24 to provide a heat transferpathway for heat conduction.

Third layer 24 is referred to, due to its color and appearance, as the“black powder” layer. Upon activation of medium 6, the atoms of thirdlayer 24, in concert with first layer 20 and second layer 22, begin tooscillate. As the heat source temperature increases, frequency ofoscillation also increases. When the activating temperature reaches 200°C., the frequency of oscillation has been calculated to be 230 milliontimes per second, and when the activating temperature is higher than350° C., the frequency of oscillation has been calculated to reach up to280 million times per second. Based on known theory, the higher theactivating temperature, the higher the frequency of oscillation.Therefore, based on this theory, the higher the load, the higher theperformance efficiency of the conduit. During the heat transfer process,there is neither phase transition nor mass transfer of medium 6.Experimentation has shown that a steel conduit 4 with medium 6 properlydisposed therein has a thermal conductivity that is generally 20,000times higher than the thermal conductivity of silver, and can reachunder laboratory conditions a thermal conductivity that is 30,000 timeshigher that the thermal conductivity of silver.

Medium 6 has a long, but limited useful life. Tests have shown thatafter 110,000 hours of continuous use, both the amount of medium 6 andthe molecule vibration frequency remain generally the same as from theinitial activation. However, at 120,000 hours of continuous use, theability of medium 6 to transfer heat starts to decline. After about123,200 hours of continuous use, medium 6 became ineffective. As isexpected, lower working temperatures slow the decline.

As disclosed generally herein, the term mixture as used herein is aportion or entire composition of matter consisting of two or morecomponents in varying proportions. Further, the individual components ofa mixture as used herein may or may not be soluble in the mixture. Amixture can include the components in solutions, suspensions, layers, orin any other arrangements or combinations thereof.

To prepare first layer 20, a first layer mixture is manufactured andthereafter applied to inner conduit surface 16. A representative firstlayer mixture is manufactured by the following steps, preferablyconducted in the order of listing:

(a) placing 100 ml of distilled water into an inert container such asglass, preferably ceramic;

(b) mixing between 2.0 and 5.0 grams of sodium peroxide into the water;

(c) mixing between 0.0 and 0.5 grams of sodium oxide into the mixture ofstep (b);

(d) mixing between 0.0 and 0.5 grams of beryllium oxide into the mixtureof step (c);

(e) mixing between 0.3 and 2.0 grams of a metal dichromate selected fromthe group consisting of aluminum dichromate and, preferably, magnesiumdichromate into the mixture of step (d);

(f) mixing between 0.0 and 3.5 grams of calcium dichromate into themixture of step (e); and

(g) mixing between 1.0 and 3.0 grams of boron oxide into the mixture ofstep (f) to form the first layer mixture.

It is preferred for the steps (a) through (g) to be conducted in theorder listed and under conditions having a temperature between 0° C. and30° C., preferably 5° C. to 8° C., and a relative humidity of no greaterthan 40%. The steps for addition of beryllium oxide and the metaldichromate can be reversed in order so that the metal dichromate isadded to the first layer mixture prior to the addition of berylliumoxide without causing negative effects. When medium 6 contains manganesesesquioxide, rhodium oxide or radium oxide, either sodium peroxide ofsodium oxide may be eliminated, but the resulting heat transferefficiency of medium 6 will be lower and the life span of medium 6 willbe reduced. As to the remaining components of the first layer mixtureand subject to the above exceptions, each component should be added inthe order presented. If the components of the first layer mixture arecombined in an order not consistent with the listed sequence, themixture can become unstable and may result in a catastrophic reaction.

The first layer mixture is termed an aqueous mixture as each of thecomponents is mixed into the water. The components may be of differingsolubility in water, with some of the components being soluble and othercomponents having low or possibly no solubility in water. Therefore,while some of the components may dissolve completely in the water,others of the components may only partially dissolve in the water, andstill others of the components may not dissolve at all in the water.Thus, it is preferable for the components to be fine powders to enhancedissolution, mixing or dispersion, as appropriate, and to enhancepenetration into the surface of a heat transfer device, as disclosedbelow. It has been found that the solubility of the components in wateris not of importance and not of interest. The combination of thecomponents resulting in the first layer mixture produces the desiredresults when applied as the first layer, as disclosed below.

Prior to manufacturing a mixture for second layer 22 and compiling thecompounds for third layer 24, rhodium and radium carbonate undergo adenaturation process. To denature 100 grams of rhodium powder, blend 2grams of pure lead powder with the rhodium powder within a container(not shown) and subsequently place the container with the rhodium andlead powders into an oven (not shown) at a temperature of 850° C. to900° C. for at least 4 hours to form rhodium oxide. Then separate therhodium oxide from the lead. To denature 100 grams of radium carbonatepowder, blend 11 grams of pure lead powder with the radium carbonatewithin a container (not shown) and subsequently place the container withthe radium carbonate and lead powders into an oven (not shown) at atemperature of 750° C. to 800° C. for at least eight hours to formradium oxide. During experimentation, a platinum container was utilizedin the denaturation process. The material comprising the containershould be inert with respect to rhodium, rhodium oxide, radiumcarbonate, radium oxide and lead. Lead utilized in the denaturationprocess preferably should be 99.9% pure and can be recycled forsubsequent use in further like denaturation processes. Subsequenttesting of medium 6 at a resting state and an active state with a PDMpersonal dosimeter (not shown) resulted in no radioactive emissions ofany kind detectable over background radiation.

An isotope of titanium is utilized in medium 6. In some countries theisotope is known as B-type titanium, and in the USA, the isotope isknown as β-titanium.

Second layer 22 is derived from a mixture that is applied to innerconduit surface 16 over first layer 20. Similar to the first layermixture, a second layer mixture is manufactured by the following steps,conducted preferably in the order of listing:

(a) placing 100 ml of twice-distilled water into an inert container suchas glass, preferably ceramic;

(b) mixing between 0.2 and 0.5 grams of cobaltous oxide into thetwice-distilled water;

(c) mixing between 0.0 and 0.5 grams of manganese sesquioxide into themixture of step (b);

(d) mixing between 0.0 and 0.01 grams of beryllium oxide into themixture of step (c);

(e) mixing between 0.0 and 0.5 grams of strontium chromate into themixture of step (d);

(f) mixing between 0.0 and 0.5 grams of strontium carbonate into themixture of step (e);

(g) mixing between 0.0 and 0.2 grams of rhodium oxide into the mixtureof step (f);

(h) mixing between 0.0 and 0.8 grams of cupric oxide into the mixture ofstep (g);

(i) mixing between 0.0 and 0.6 grams of β-titanium into the mixture ofstep (h);

(j) mixing between 1.0 and 1.2 grams of potassium dichromate into themixture of step (i);

(k) mixing between 0.0 and 1.0 grams of boron oxide into the mixture ofstep (j);

(l) mixing between 0.0 and 1.0 grams of calcium dichromate into themixture of step (k); and

(m) mixing between 0.0 and 2.0 grams of aluminum dichromate or,preferably, magnesium dichromate, into the mixture of step (l) to formthe second layer mixture.

It is preferred for the twice-distilled water to have an electricalconductivity that approaches 0. The higher the electrical conductivity,the greater the problem of static electricity interfering with medium 6and causing a reduction in the thermal conductive efficiency. The stepsof (a) through (m) are preferably conducted under conditions having atemperature between 0° C. and 30° C. and a relative humidity of nogreater than 40%. When medium 6 contains rhodium oxide or radium oxide,the amount of manganese sesquioxide may be reduced or eliminated;however, the life span of medium 6 will be reduced and the thermalconductive efficiency will be reduced. Generally, β-titanium may beadded to the second layer mixture at any step listed above, except thatit should not be added to the twice-distilled water at step (b) or asthe last component of the mixture. Adding β-titanium at step (b) or asthe last component of the mixture can cause instability of the secondlayer mixture and may result in a catastrophic reaction. The steps foradding manganese sesquioxide and beryllium oxide may be reversed inorder so that beryllium oxide is added to the second layer mixture priorto the addition of manganese sesquioxide. Likewise, the steps for addingpotassium dichromate and calcium dichromate may be reversed in order sothat calcium dichromate is added to the second layer mixture prior tothe addition of potassium dichromate. If the components of the secondlayer mixture are is combined in an order not consistent with the listedsequence and the exceptions noted above, the mixture can become unstableand may result in a catastrophic reaction.

The second layer mixture also is termed an aqueous mixture as each ofthe components is mixed into the water. The components also may be ofdiffering solubility in water, with some of the components being solubleand other components having low or possibly no solubility in water.Therefore, while some of the components may dissolve completely in thewater, others of the components may only partially dissolve in thewater, and still others of the components may not dissolve at all in thewater. Thus, it is preferable for the components to be fine powders toenhance dissolution, mixing or dispersion, as appropriate. It has beenfound that the solubility of the components in water is not ofimportance and not of interest. The combination of the componentsresulting in the second layer mixture produces the desired results whenapplied as the second layer, as disclosed below.

Prior to preparing third layer 24, silicon is treated by magneticpenetration. Monocrystalline silicon powder having a preferred purity of99.999% is placed within a non-magnetic container (not shown) anddisposed within a magnetic resonator (not shown) for at least 37minutes, preferably 40 minutes to 45 minutes. The magnetic resonatorutilized during experimentation is a 0.5 kilowatt, 220 volt and 50 hertzmagnetic resonator. If the silicon being used has a lower purity that99.999%, the amount of silicon needed in third layer 24 increases. Themagnetic resonator is used to increase the atomic electron layer of thesilicon, which in turn, increases the speed that heat is conducted bymedium 6.

A representative powder of third layer 24 is manufactured by thefollowing steps, preferably conducted in the order of listing:

(a) placing between 0.0 and 1.75 grams of denatured rhodium oxide intoan inert container such as glass, preferably ceramic;

(b) blending between 0.3 and 2.6 grams of sodium dichromate with therhodium oxide;

(c) blending between 0.0 and 0.8 grams of potassium dichromate with themixture of step (b);

(d) blending between 0.0 and 3.1 grams of denatured radium oxide withthe mixture of step (c);

(e) blending between 0.1 and 0.4 grams of silver dichromate with themixture of step (d);

(f) blending between 0.2 and 0.9 grams of the monocrystalline siliconpowder treated by magnetic penetration with the mixture of step (e);

(g) blending between 0.0 and 0.01 grams of beryllium oxide with themixture of step (f);

(h) blending between 0.0 and 0.1 grams of strontium chromate with themixture of step (g);

(i) blending between 0.0 and 0.1 grams of boron oxide with the mixtureof step (h);

(j) blending between 0.0 and 0.1 grams of sodium peroxide with themixture of step (i);

(k) blending between 0.0 and 1.25 grams of β-titanium with the mixtureof step (i); and

(l) blending between 0.0 and 0.2 grams of aluminum dichromate or,preferably, magnesium dichromate, into the mixture of step (k) to formthe third layer powder.

The powder for third layer 24 preferably should be blended at atemperature lower than about 25° C. By blending at lower temperatures,the heat conducting efficiency of medium 6 improves. Further, therelative humidity should be below 40%. It is preferred for the relativehumidity to be between 30% and 35%. Generally, radium oxide andβ-titanium may be added to the powder of third layer 24 at any steplisted above, except that neither one should be added to the powder asthe first or last component. Adding either radium oxide or β-titanium asthe first or last component of the powder can cause instability ofmedium 6 and may result in a catastrophic reaction. The steps for addingpotassium dichromate and silver dichromate may be reversed in order sothat silver dichromate is added to the powder of third layer 24 prior tothe addition of potassium dichromate. Likewise, the steps for addingstrontium chromate and beryllium oxide may be reversed in order so thatberyllium oxide is added to the powder of third layer 24 prior to theaddition of strontium chromate. If the components of the powder of thirdlayer 24 are combined in an order not consistent with the listedsequence and the exceptions noted above, medium 6 can become unstableand may result in a catastrophic reaction.

The powder of third layer 24 can be stored for prolonged periods oftime. To prevent degradation by light and humidity, the powder of thirdlayer 24 should be stored in a dark, hermetic storage container (notshown) made from an inert material, preferably glass. A moistureabsorbing material also may be placed within the storage container solong as the moisture absorbing material is inert to and is notintermingled with the powder of third layer 24.

Once the mixtures for first layer 20 and second layer 22 and the powderof third layer 24 are prepared, the heat transfer device 2 can befabricated. Conduit 4 can be any one of a variety of metallic ornon-metallic materials and should have very little oxidation, preferablyno oxidation, on inner conduit surface 16. It is recommended for conduit4 to be clean, dry and free of any oxides or oxates, particularly ifconduit 4 is manufactured of a metal. This can be accomplished byconventional treatment by, for example, sand blasting, weak acidwashing, or weak base washing. Any materials used to clean and treatconduit 4 should be completely removed and inner conduit surface 16 alsoshould be dry prior to adding medium 6 to conduit 4. Additionally, thewall thickness of conduit 4 should be selected to take a wear rate of atleast 0.1 mm per year into account. This wearing is caused by theoscillation of third layer's 24 molecules. For steel, the wall thicknessshould be at least 3 mm. Obviously, softer materials need to be thicker.The conduit 4 may be of considerable length. In fact, it has been foundthat the performance efficiency of the conduit 4 increases with length.

A representative heat transfer device 2 is manufactured utilizing thefollowing steps:

(a) placing the first layer mixture into a first layer mixturecontainer;

(b) submerging conduit 4 having cavity 8 within the first layer mixturesuch that the first layer mixture fills cavity 8, conduit 4 preferablyhaving a non-horizontal placement both within the first layer mixtureand relative to the earth, conduit 4 also having a lower end 26, at atemperature between 0° C. and 30° C. for at least 8 hours so that atleast a portion of the first layer mixture can at least partiallypenetrate the wall of conduit 4 to a depth of between 0.008 mm and 0.012mm, and then removing conduit 4 from first layer mixture;

(c) drying conduit 4 naturally at ambient conditions to form first layer20 within cavity 8;

(d) placing the second layer mixture into a second layer mixturecontainer:

(e) submerging conduit 4 with first layer 20 within the second layermixture such that the second layer mixture fills cavity 8, lower end 26being oriented in a downward direction, at a temperature between 55° C.and 65° C., preferably 60° C., for at least 4 hours, and then removingconduit 4 from second layer mixture;

(f) drying conduit 4 naturally at ambient conditions to form a film ofsecond layer 22 within cavity 8 having a thickness between 0.008 mm and0.012 mm;

(g) welding an end cap 28 on the opposite end of conduit 8 from lowerend 26 by a precision welding technique, preferably heli-arc weldingdone in the presence of helium or argon;

(h) welding an injection cap 30 having a bore 32 between 2.4 mm and 3.5mm, preferably 3.0 mm, on lower end 26 preferably by the method utilizedin step (g);

(i) heating lower end 26 to a temperature not to exceed 120° C.,preferably 40° C.;

(j) injecting the powder of third layer 24 through bore 32 in an amountof at least 1 cubic meter per 400,000 cubic meters of cavity 8 volume;

(k) inserting plug 34, preferably conical-shaped and solid plug 34, asshown in FIG. 3, into bore 32;

(l) heating lower end 26 to a temperature between 80° C. and 125° C.;

(m) removing plug 34 from bore 32 for no more than 3 seconds, preferably2 seconds, and reinserting plug 34 into bore 32; and

(n) sealing plug 34 within bore 32, preferably by the method utilized instep (g), to form heat transfer device 2.

If the temperature of lower end 26 in step (i) exceeds 60° C., lower end26 should be allowed to cool to at least 60° C. prior to injecting thepowder of third layer 24 into cavity 8. By following the steps above,lower end 26 becomes heat polarized. In other words, lower end 26 ispolarized to receive heat from the heat source and transfer the heataway from lower end 26.

The purpose of removing plug 34 from bore 32 in step (m) above is torelease air and water molecules from cavity 8 of conduit 4 to theoutside environment. A blue gas has been observed exiting bore 32 onceplug 34 is removed. However, if a blue light is observed emitting frombore 32 prior to plug 34 being reinserted into bore 32, the powder ofthird layer 24 has escaped to the atmosphere and steps (j) through (m)need to be repeated. If step (j) can be accomplished in a humidity-freeenvironment under a partial vacuum, steps (l) and (m) can be eliminated,but it is not recommended.

Manganese sesquioxide, rhodium oxide, and radium oxide are not needed inall applications of medium 6. These three components are used in medium6 when heat transfer device 2 is exposed to an environment ofhigh-pressure steam is and conduit 4 is manufactured of high carbonsteel. In this special case, high pressure is defined as being 0.92million Pascal or higher. Manganese sesquioxide, rhodium oxide, andradium oxide are not needed and may be eliminated from medium 6 when theuse of heat transfer device 2 is not in a high pressure steamenvironment, even if conduit 4 is made of high carbon steel.Additionally, when manganese sesquioxide, rhodium oxide, and radiumoxide are eliminated from medium 6, the powder of third layer 24 shouldbe provided in an amount of 1 cubic meter of third layer powder per200,000 cubic meters of cavity 8 volume.

As disclosed above, heat sink 12 utilizes heat transfer medium 6. Arepresentative heat sink 12 is manufactured utilizing the followingsteps:

(a) placing the first layer mixture into a first layer mixturecontainer;

(b) submerging first plate 36 and second plate 38 within the first layermixture such that the first layer mixture covers at least one side ofeach of first plate 36 and second plate 38 at a temperature between 0°C. and 30° C. for at least 8 hours so that at least a portion of thefirst layer mixture can at least partially penetrate the first layermixture covered side 40 to a depth between 0.008 mm and 0.012 mm, firstplate 36 and second plate 38 having mating edges 42 and forming arelatively small volume cavity 8 with respect to the surface area offirst plate 36 and second plate 38 when first plate 36 and second plate38 are placed together, and at least one of first plate 36 and secondplate 38 has an opening 44 between 2.4 mm and 3.5 mm, preferably 3.0 mm,and then removing first plate 36 and second plate 38 from the firstlayer mixture;

(c) drying first plate 36 and second plate 38 naturally at ambientconditions to form first layer 20 on the first layer covered sides 40 offirst plate 36 and second plate 38;

(d) placing the second layer mixture into a second layer mixturecontainer;

(e) submerging first plate 36 and second plate 38 within the secondlayer mixture such that the second layer mixture contacts first layer 20at a temperature between 55° C. and 65° C., preferably 60° C., for atleast 4 hours, and then removing first plate 36 and second plate 38 fromthe second layer mixture;

(f) drying first plate 36 and second plate 38 naturally at ambientconditions to form the film of second layer 22 having a thicknessbetween 0.008 mm and 0.012 mm on first layer 20;

(g) welding first plate 36 and second plate 38 together along matingedges 42 by a precision welding technique, preferably heli-arc weldingdone in the presence of helium or argon, so that the first layer coveredsides 40 face one another;

(h) injecting the powder of third layer 24 into cavity 8 through opening44 in an amount of at least 1 cubic meter per 400,000 cubic meters ofcavity volume; and

(i) sealing opening 44 preferably by the method utilized in step (g) toform heat sink 12.

Heat sink 12 can be manufactured in the same manner as heat transferdevice 2; that is, heat sink 12 may be heat polarized, but it is notnecessary. Also, the steps calling for welding in the manufacture ofheat transfer device 2 and heat sink 12 can be accomplished by usingglues, adhesives and/or epoxies, preferably heat tolerant glues,adhesives and epoxies. Additionally, all welding should be conducted toa depth of two-thirds of the thickness of conduit 4, end cap 28,injection cap 30, first plate 36 or second plate 38. After welding, aleakage test, such as the Helium Vacuum Leakage Test, should beperformed.

All materials comprising conduit 4, end cap 28, injection cap 30 andplug 34 of heat transfer device 2 or first plate 36 and second plate 38of heat sink 12 should be compatible with one another. This preventsproblems, particularly material fractures, associated with the differentexpansion/contraction rates of different materials used in combinationand corrosion associated with anodic reactions. The material selectedalso should be compatible with and able to withstand the externalenvironment in which heat transfer device 2 or heat sink 12 operates.For example, if heat transfer device 2 is operating in an acidicenvironment, the material should be resistant to the acid present.

Heat transfer medium 6 also can conduct cold temperature transfer when acold source is exposed to either end of conduit 4. Cold temperatureshave been successfully transferred across conduit 4 when one end thereofcame in contact with liquid nitrogen having a temperature of −195° C.

The invention will be better understood by reference to the followingillustrated examples. With respect to the above description then, it isto be realized that the optimum dimensional relationships for the partsof the invention, to include variations in size, materials, shape, form,function and manner of operation, assembly and use, are deemed readilyapparent and obvious to on skilled in the art, and all equivalentrelationships to those described in the specification are intended to beencompassed by the present invention.

The following examples describe various compositions of first layer 20,second layer 22 and third layer 24 and are known to be useful inpreparing a superconducting heat transfer device 2 or heat sink 12. Thecomponents preferably are added to the respective layers 20, 22, 24 inthe amounts listed, in the order of listing and in accordance with therespective steps described above.

EXAMPLE 1

For forming first layer 20, into 100 ml of distilled water add 5.0 gramsof sodium peroxide, 0.5 gram of sodium oxide, 2.0 grams of magnesiumdichromate or aluminum dichromate, 2.5 grams of calcium dichromate and3.0 grams of boron oxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.5 gram of cobaltous oxide, 0.5 gram of manganese sesquioxide, 0.5 gramof strontium carbonate, 0.2 gram of rhodium oxide, 0.8 gram of cupricoxide, 0.6 gram of β-titanium and 1.2 grams of potassium dichromate.

For forming the powder of third layer 24, combine 1.75 grams of rhodiumoxide, 1.25 grams of β-titanium, 3.1 grams of radium oxide, 2.6 grams ofsodium dichromate, 0.4 gram of silver dichromate and 0.9 gram ofmonocrystalline silicon powder.

EXAMPLE 2

For forming first layer 20, into 100 ml of distilled water add 5.0 gramsof sodium peroxide, 0.5 gram of beryllium oxide, 2.0 grams of magnesiumdichromate, 2.0 grams of calcium dichromate and 3.0 grams of boronoxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.5 gram of cobaltous oxide, 0.5 gram of strontium chromate, 0.8 gram ofcupric oxide, 0.6 gram of β-titanium and 1.2 grams of potassiumdichromate.

For forming the powder of third layer 24, combine 1.6 grams of sodiumdichromate, 0.8 gram of potassium dichromate, 0.4 gram of silverdichromate and 0.9 gram of monocrystalline silicon powder.

EXAMPLE 3

For forming first layer 20, into 100 ml of distilled water add 5.0 gramsof sodium peroxide, 0.5 gram of beryllium oxide, 2.0 grams of magnesiumdichromate, 3.5 grams of calcium dichromate and 3.0 grams of boronoxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.5 gram of cobaltous oxide, 0.5 gram of strontium chromate, 0.8 gram ofcupric oxide, 0.6 gram of β-titanium and 1.2 grams of potassiumdichromate.

For forming the powder of third layer 24, combine 1.6 grams of sodiumdichromate, 0.8 gram of potassium dichromate, 0.6 gram of silverdichromate and 0.9 gram of monocrystalline silicon powder.

EXAMPLE 4

For forming first layer 20, into 100 ml of distilled water add 2.0 gramsof sodium peroxide, 0.3 gram of beryllium oxide, 2.0 grams of magnesiumdichromate, and 1.0 gram of boron oxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.5 gram of cobaltous oxide, 0.5 gram of strontium chromate, 0.4 gram ofβ-titanium and 1.0 gram of potassium dichromate.

For forming the powder of third layer 24, combine 0.5 gram of sodiumdichromate, 0.8 gram of potassium dichromate, 0.1 gram of silverdichromate, 0.3 gram of monocrystalline silicon powder, 0.01 gram ofberyllium oxide, 0.1 gram of strontium chromate, 0.1 gram of boron oxideand 0.1 gram of sodium peroxide.

EXAMPLE 5

For forming first layer 20, into 100 ml of distilled water add 2.0 gramsof sodium peroxide, 0.3 gram of beryllium oxide, 2.0 grams of magnesiumdichromate and 1.0 gram of boron oxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.3 gram of cobaltous oxide, 0.3 gram of strontium chromate, 1.0 gram ofpotassium dichromate and 1.0 gram of calcium dichromate.

For forming the powder of third layer 24, combine 0.3 gram of sodiumdichromate, 0.1 gram of silver dichromate, 0.8 gram of potassiumdichromate, 0.2 gram of monocrystalline silicon powder, 0.01 gram ofberyllium oxide, 0.1 gram of strontium chromate, 0.1 gram of boronoxide, 0.2 gram of β-titanium and 0.1 gram of sodium peroxide.

EXAMPLE 6

For forming first layer 20, into 100 ml of distilled water add 2.0 gramsof sodium peroxide, 0.3 gram of magnesium dichromate, 1.0 gram of boronoxide and 1.0 gram of calcium dichromate.

For forming second layer 22, into 100 ml of twice-distilled water add0.3 gram of cobaltous oxide, 0.01 gram of beryllium oxide, 1.0 gram ofpotassium dichromate, 1.0 gram of boron oxide and 2.0 grams of magnesiumdichromate.

For forming the powder of third layer 24, combine 0.3 gram of sodiumdichromate, 0.1 gram of silver dichromate, 0.8 gram of potassiumdichromate, 0.2 gram of monocrystalline silicon powder, 0.1 gram ofstrontium chromate, 0.01 gram of beryllium oxide, 0.1 gram of boronoxide, 0.1 gram of sodium peroxide, 0.2 gram of β-titanium and 0.2 gramof magnesium dichromate.

EXAMPLE 7

For forming first layer, into 100 ml of distilled water add 2.0 grams ofsodium peroxide, 0.3 gram of magnesium dichromate and 1.0 gram of boronoxide.

For forming second layer 22, into 100 ml of twice-distilled water add0.2 gram of cobaltous oxide, 1.0 gram of calcium dichromate, 1.0 gram ofpotassium dichromate, 0.5 gram of boron oxide, 1.0 gram of magnesiumdichromate and 0.01 gram of beryllium oxide.

For forming the powder of third layer 24, combine 0.3 gram of sodiumdichromate, 0.05 gram of silver dichromate, 0.8 gram of potassiumdichromate, 0.2 gram of monocrystalline silicon powder, 0.1 gram ofstrontium chromate, 0.01 gram of beryllium oxide, 0.1 gram of boronoxide, 0.1 gram of sodium peroxide, 0.2 gram of β-titanium and 0.2 gramof magnesium dichromate.

EXPERIMENTAL

1. Introduction

Adding an appropriate quantity, on the order of several milligrams, ofthird layer 24 powder, which is an inorganic thermal superconductivemedium to pipe, such as conduit 4, or flat interlayed piece, such asplates 36, 38, that already has been treated with the first layermixture and the second layer mixture, creates a superconductive heattransfer device 2. For example, the addition of the third layer 24powder into the cavity 6 of the conduit 4 or between the plates 36, 38and then sealing the cavity 6 after subsequently eliminating theresidual water and air upon heating, will create a heat transfer device2. Subsequent test results illustrate that third layer 24 is asuperconductive medium and that a heat-conducting device made of thirdlayer 24 is a thermal superconductive heat pipe.

The fact that a conventional heat pipe shares a similar outside shape toa thermal superconductive heat pipe used to raise somemisunderstandings. Therefore, it is necessary to give a briefdescription on the differences and similarities of the two. Aconventional heat pipe makes use of the technique of liquids vaporizingupon absorbing great amounts of heat and vapors cooling upon emittingheat so as to bring the heat from the pipe's hot end to its cold end.The axial heat conducting velocity of the heat pipe depends on the valueof the liquid's vaporization potent heat and the circulation speedbetween two forms of liquid and vapor. The axial heat conductingvelocity of the heat pipe also is restrained by the type and quantity ofthe carrier material and the temperatures and pressures at which theheat pipe operates (it can not be too high). The present heat transferdevice 2 is made of a heat transfer medium whose axial heat conductionis accomplished by the heat transfer mediums' molecules high-speedmovement upon being heated and activated. The present heat transferdevice's 2 heat conducting velocity is much higher than that of anymetal bars or any conventional heat pipes of similar size, thus the termsuperconducting or superconductive, while its internal pressure is muchlower than that of any convectional heat pipe of the same temperature.The applicable upper temperature limit of the present heat transferdevice 2 is beyond the allowed upper temperature limit of the conduit 4material.

The heat transfer device 2 made from the method disclosed herein caninfluence most if not all categories of heat transfer, especially on theheat utilization ratio. The heat transfer device 2 made from the methoddisclosed herein also is applicable in the development and utilizationof solar energy and geothermal energy, and for the recycling of lowerenergy level heat.

2. Testing Method and Principle

The heat conducting velocity of a metal bar depends on the bar's heatconductivity, temperature gradient and the cross-sectional areaorthogonal to the temperature gradient. Metals have higher heatconductivities than nonmetal solids. Among metals, silver has thehighest heat conductivity of about 415 W/mK. The heat transfer devices 2produced from the present inventive method are an entirely newdevelopment. However, it does appear that using the measurements oftheir effective or apparent heat conductivities and axial and radialheat fluxes as an indication of their properties is scientific andlogical.

The testing method used to test the properties of the present heattransfer devices 2 employed an upgrade Forbes Method, in which a thermalsuperconductive heat pipe was taken to be a semi-infinite rod. Giventhat the temperature of the rod's reference surface is T₀ K, thetemperature of a cross-section×meters away from the reference surface isT K, the temperature of the fluid (water) which is adjacent to the rodsurface and which undergoes heat convection between itself and the rodis T_(t) K, the heat conductivity of the rod is k W/mK, the convectionalheat transfer coefficient of the surface is h W/m² K, the girth of therod is P meters, and the cross-sectional area of the rod is f m², theprincipal differential equation of heat transfer isd ² T/dx ²−(h·p)/(k·f)·(T−T _(∞))=0  (1)

This is a heterogeneous differential equation. Suppose ⊖=T−T_(∞) andEquation (1) then transforms into a homogeneous equation, by assumingm²=hp/kf, we haved ² ⊖/dx ² −m ²⊖=0  (2)

For cylindrical objects, m²=4h/(kd₀), where d₀ is the diameter of thecylindrical object.

Suppose⊖=⊖₀ at x=0  (3)⊖=0 at x=∞  (4)

The solution that satisfies the above boundary conditions is⊖=⊖₀ ^((−mx))  (5)

Under the boundary condition defined by Equations (6) and (7)⊖=⊖₀ at x=0  (6)d⊖/dx=0 at x=L  (7)then another solution of Equation (2) is⊖/⊖₀ =Exp(−mx){[1+Exp(2m(L−x))]/[1+Exp(2mL)]}  (8)

Since some experimental conditions may appear similar to that specifiedby Equations (6) and (7), and the value of the expression inside thesquare brackets is close to 1, therefore we have⊖/⊖₀ =Exp(−mx)  (9)which also is correct.

The axial heat conducting velocity across the reference surface isQ _(x) =−kf(d⊖/dx)_(x=0)  (10)

From Equation (5), we can deduce the following(d⊖/dx)_(x=0)=−⊖₀ mExp(−mx)|_(x=0)=−⊖₀ m  (11)

By substitution with Equation (6), we haveQ ₀ =k·f·m·⊖ ₀  (12)

The speed of heat flux from rod to water isQ ₀ =V·ρ·C _(p)·(T ₀ −T _(i)) watts  (13)where

V=volume flow rate of water (m³/s)

ρ=density of water (kg/m³)

C_(p)=specific heat of water (J/kgK)

T_(o)=outlet temperature of water (K)

T_(i)=inlet temperature of water (K)

andQ _(i) =d ₀ πLhΔt _(ln)  (14)where

L=length of the rod (meters)

d₀=outer diameter of the rod (meters)

h=convectional heat transfer coefficient (W/m²K)

Δt _(ln)=(⊖₀−⊖_(L)ln(⊖) _(o)/⊖_(L))

Upon having measured the above quantities, the effective heatconductivity of a thermal superconductive heat pipe can be calculatedand the heat flux also can be calculated.

3. Testing apparatus

Based on the above mentioned testing principle and mathematical model, atesting apparatus, as shown in FIG. 7, comprising the thermal heatconductive pipe 102, cooling water casing pipe 104, thermocouples 106,pressure gauge 108, water vapor heating chamber 110, condensed watercollector 112, and evacuation valve 114 was assembled.

4. Testing results

There are many advantages to using saturated water vapor as the heatsource to activate the heat transfer medium 24 inside the heat transferdevice 2. Saturated water vapor has a higher condensing heat transfercoefficient and the saturated water vapor comes into direct contact withthe heated surface of the heat transfer device 2 exclusive of contactheat resistance. Keeping the pressure of the saturated water vapor undercontrol means keeping the heating temperature under control, and canprovide the heat transfer device 2 with a stable heat flux. After theflow rate and the inlet temperature of the cooling water is specified,the testing system will come into a stable equilibrium. All of thephysical quantities that are measured are stable and well repeatable.

The following chart illustrates four representative groups of measuredresults, and FIGS. 8-11 show these results graphically.

Results of Measurement Axial Heat Radial Heat Effective Heat No. Flux(W/m²) Flux (W/m²) Conductivity (W/mK) k/k_(Ag) 1 8.618 × 10⁶ 4.396 ×10⁴ 1.969 × 10⁶ 4.746 × 10³ 2 8.363 × 10⁶ 4.267 × 10⁴ 3.183 × 10⁶ 7.672× 10³ 3 8.260 × 10⁶ 4.214 × 10⁴ 2.624 × 10⁵ 6.324 × 10² 4 8.831 × 10⁶4.505 × 10⁴ 3.235 × 10⁴ 7.795 × 10²

The temperature distribution curve, effective heat conductivity,convectional heat transfer coefficient of the pipe surface of thecooling segment, and heat conducting velocity were obtained underdifferent cooling water flow rates. Although these values show certaindifferences, they indicate that the heat pipe is thermallysuperconductive.

Changes of cooling water flow rates causes changes in temperaturedistribution, but no changes in heat conducting velocity. This meansthat the heat conducting velocity in the heating segment has reached itsupper limit. That the heat conducting area of the heating segment wasdesigned not great enough was due to the underestimation of the heatconducting capability of the heat pipe. Changes in temperaturedistribution brought changes in the value and sign of slope m in thecorrelation equation. That the convectional heat transfer coefficientwas changed means that the effective heat conductivity also was changed.The thermal superconductivity of the heat pipe is confirmed by thesechanges. When m has a plus sign, the outlet temperature of the coolingwater approaches the temperature at the base of the heat pipe (at x=0).A conventional heat exchanger can attain such a high heat transferefficiency only under the condition of counter flow. If the coolingwater flow rate is increased, then the outlet temperature of the coolingwater approaches that at the other end (x=L). A conventional heatexchanger can reach such a great heat transfer efficiency only when theheat conducting area is infinite.

Therefore, the foregoing, including the examples, is considered asillustrative only of the principles of the invention. Further, variousmodifications may be made of the invention without departing from thescope thereof and it is desired, therefore, that only such limitationsshall be placed thereon as are imposed by the prior art and which areset forth in the appended claims.

1. A method for producing a heat transfer medium comprising threelayers, comprising the steps of: (a) preparing a first layer mixturecomprising water, beryllium oxide, a metal dichromate, calciumdichromate, and boron oxide; (b) applying the first layer mixture to asurface of a substrate so as to form a first layer; (c) preparing asecond layer mixture; (d) applying the second layer mixture to the firstlayer so as to form a second layer on top of the first layer; (e)preparing a third layer powder; and (f) exposing the second layer to thethird layer powder so as to form a third layer on top of the secondlayer, thus forming the three layer heat transfer medium.
 2. The methodfor producing the heat transfer medium of claim 1, wherein the firstlayer mixture further comprises one or more sodium compounds selectedfrom the group consisting of sodium peroxide and sodium oxide.
 3. Themethod for producing the heat transfer medium of claim 2, wherein themetal dichromate of the first layer mixture is selected from the groupconsisting of aluminum dichromate and magnesium dichromate.
 4. Themethod for producing the heat transfer medium of claim 3, wherein thesecond layer is prepared from a mixture comprising water, cobaltousoxide, manganese sesquioxide, beryllium oxide, strontium chromate,strontium carbonate, cupric oxide, titanium, potassium dichromate, boronoxide, calcium dichromate, and a metal dichromate.
 5. The method forproducing the heat transfer medium of claim 4, wherein the metaldichromate of the second layer mixture is selected from the groupconsisting of aluminum dichromate and magnesium dichromate, and thetitanium is β-titanium.
 6. A method for producing a heat transfer mediumcomprising three layers, comprising the steps of: (a) preparing a firstlayer mixture; (b) applying the first layer mixture to a surface of asubstrate so as to form a first layer; (c) preparing a second layermixture comprising water, cobaltous oxide, beryllium oxide, strontiumchromate, strontium carbonate, cupric oxide, titanium, potassiumdichromate, boron oxide, calcium dichromate, a metal dichromate, and oneor more oxides selected from the group consisting of rhodium oxide andradium oxide; (d) applying the second layer mixture to the first layerso as to form a second layer on top of the first layer; (e) preparing athird layer powder; and (f) exposing the second layer to the third layerpowder so as to form a third layer on top of the second layer, thusforming the three layer heat transfer medium.
 7. The method forproducing the heat transfer medium of claim 6, wherein the metaldichromate is selected from the group consisting of aluminum dichromateand magnesium dichromate, and the titanium is β-titanium.
 8. The methodfor producing the heat transfer medium of claim 7, wherein the secondlayer mixture further comprises magnesium sesquioxide.
 9. A method forproducing a heat transfer medium comprising three layers, comprising thesteps of: (a) preparing a first layer mixture; (b) applying the firstlayer mixture to a surface of a substrate so as to form a first layer;(c) preparing a second layer mixture; (d) applying the second layermixture to the first layer so as to form a second layer on top of thefirst layer; (e) preparing a third layer powder from a blend comprisingone or more denatured oxides selected from the group consisting ofdenatured rhodium oxide, denatured radium oxide, and combinationsthereof; one or more Group IA dichromates selected from the groupconsisting of sodium dichromate, potassium dichromate, and combinationsthereof; silver dichromate; monocrystalline silicon; beryllium oxide;strontium chromate; boron oxide; sodium peroxide; titanium; and a metaldichromate; and (f) exposing the second layer to the third layer powderso as to form a third layer on top of the second layer, thus forming thethree layer heat transfer medium.
 10. The method for producing the heattransfer medium of claim 9, wherein the metal dichromate is selectedfrom the group consisting of aluminum dichromate and magnesiumdichromate, and the titanium is β-titanium.
 11. A method for producing aheat transfer medium comprising three layers, comprising the steps of:(a) preparing a first layer mixture by a process comprising the stepsof: (i) placing 100 parts, by weight, of distilled water into an inertcontainer; (ii) mixing between 2.0 and 5.0 parts, by weight, of sodiumperoxide into the water; (iii) mixing between 0.0 and 0.5 parts, byweight, of sodium oxide into the mixture of step (b); (iv) mixingbetween 0.0 and 0.5 parts, by weight, of beryllium oxide into themixture of step (c); (v) mixing between 0.3 and 2.0 parts, by weight, ofa metal dichromate selected from the group consisting of aluminumdichromate and magnesium dichromate into the mixture of step (d); (vi)mixing between 0.0 and 3.5 parts, by weight, of calcium dichromate intothe mixture of step (e); and (vii) mixing between 1.0 and 3.0 parts, byweight, of boron oxide into the mixture of step (f); (b) applying thefirst layer mixture to a surface of a substrate so as to form a firstlayer; (c) preparing a second layer mixture; (d) applying the secondlayer mixture to the first layer so as to form a second layer on top ofthe first layer; (e) preparing a third layer powder; and (f) exposingthe second layer to the third layer powder so as to form a third layeron top of the second layer, thus forming the three layer heat transfermedium.
 12. The method for producing the heat transfer medium of claim11, wherein the step of preparing the second layer mixture comprises thesteps of: (a) placing 100 parts, by weight, of twice-distilled waterinto an inert container; (b) dissolving and mixing between 0.2 and 0.5parts, by weight, of cobaltous oxide into the twice-distilled water; (c)mixing between 0.0 and 0.5 parts, by weight, of manganese sesquioxideinto the mixture of step (b); (d) mixing between 0.0 and 0.01 parts, byweight, of beryllium oxide into the mixture of step (c); (e) mixingbetween 0.0 and 0.5 parts, by weight, of strontium chromate into themixture of step (d); (f) mixing between 0.0 and 0.5 parts, by weight, ofstrontium carbonate into the mixture of step (e); (g) mixing between 0.0and 0.2 parts, by weight, of rhodium oxide into the mixture of step (f);(h) mixing between 0.0 and 0.8 parts, by weight, of cupric oxide intothe mixture of step (g); (i) mixing between 0.0 and 0.6 parts, byweight, of β-titanium into the mixture of step (h); (j) mixing between1.0 and 1.2 parts, by weight, of potassium dichromate into the mixtureof step (i); (k) mixing between 0.0 and 1.0 parts, by weight, of boronoxide into the mixture of step (j); (l) mixing between 0.0 and 1.0parts, by weight, of calcium dichromate into the mixture of step (k);and (m) mixing between 0.0 and 2.0 parts, by weight, of a compoundselected from the group consisting of aluminum dichromate and magnesiumdichromate, into the mixture of step (l).
 13. The method for producingthe heat transfer medium of claim 12, wherein the step of preparing thethird layer powder comprises the steps of: (a) placing between 0.0 and1.75 parts, by weight, of denatured rhodium oxide into an inertcontainer; (b) blending between 0.3 and 2.6 parts, by weight, of sodiumdichromate with the rhodium oxide; (c) blending between 0.0 and 0.8parts, by weight, of potassium dichromate with the mixture of step (b);(d) blending between 0.0 and 3.1 parts, by weight, of denatured radiumoxide with the mixture of step (c); (e) blending between 0.1 and 0.4parts, by weight, of silver dichromate with the mixture of step (d); (f)blending between 0.2 and 0.9 parts, by weight, of the monocrystallinesilicon powder treated by magnetic penetration with the mixture of step(e); (g) blending between 0.0 and 0.01 parts, by weight, of berylliumoxide with the mixture of step (f); (h) blending between 0.0 and 0.1parts, by weight, of strontium chromate with the mixture of step (g);(i) blending between 0.0 and 0.1 parts, by weight, of boron oxide withthe mixture of step (h); (j) blending between 0.0 and 0.1 parts, byweight, of sodium peroxide with the mixture of step (i); (k) blendingbetween 0.0 and 1.25 parts, by weight, of β-titanium with the mixture ofstep (j); and (l) blending between 0.0 and 0.2 parts, by weight, of acompound selected from the group consisting of aluminum dichromate andmagnesium dichromate, into the mixture of step (k).
 14. The method forproducing the heat transfer medium of claim 13, wherein: said step ofapplying the first layer comprises the steps of (1) submerging at leasta portion of the substrate within the first layer mixture such that thefirst layer mixture contacts at least a selected portion of thesubstrate; and (2) drying the substrate naturally at ambient conditionsto form first layer on the selected portion of the substrate; said stepof applying the second layer comprises the steps of (1) submerging atleast a portion of the substrate with the first layer thereon within thesecond layer mixture such that the second layer mixture contacts atleast a selected portion of the first layer; and (2) drying thesubstrate naturally at ambient conditions to form a film of second layeron the selected portion of the first layer; and said step of applyingthe third layer comprises the step of exposing at least a selectedportion of the second layer to the third layer powder.
 15. The methodfor producing the heat transfer medium of claim 14, wherein said step ofapplying the first layer mixture is carried out at a temperature ofbetween about 0° C. and about 30° C. for at least 8 hours.
 16. Themethod for producing the heat transfer medium of claim 14, wherein saidstep of applying the third layer is carried out at a temperature ofbetween about 55° C. and about 65° C. for at least 4 hours.
 17. A methodfor producing a heat transfer device comprising the heat transfer mediumof claim 13, wherein: said step of applying said first layer comprisesthe steps of (1) submerging a substrate having a cavity and first andsecond ends within the first layer mixture such that the first layermixture fills the cavity; and (2) drying the substrate naturally atambient conditions to form the first layer within the cavity; said stepof applying said second layer comprises the steps of (1) submerging thesubstrate within the second layer mixture such that the second layermixture fills the cavity; (2) drying the substrate naturally at ambientconditions to form a film of the second layer within the cavity; (3)attaching an end cap on the second end of the substrate; (4) attachingan injection cap having a bore therethrough on the first end of thesubstrate; and (5) heating the first end of the substrate to atemperature not to exceed 120° C.; and said step of applying said thirdlayer comprises the steps of (1) injecting the third layer powderthrough the bore in an amount of at least 1 cubic meter per 400,000cubic meters of the cavity volume; (2) inserting a plug into the bore;(3) heating the first end of the substrate to a temperature betweenabout 80° C. and about 125° C.; (4) removing the plug from the bore; and(5) reinserting the plug into the bore.
 18. The method for producing aheat transfer device of claim 17, wherein the substrate is placed withinthe first layer mixture in a non-horizontal arrangement at a temperatureof between about 0° C. and about 30° C. for at least 8 hours, and thefirst layer mixture penetrates the surface of the substrate to a depthof between 0.008 mm and 0.012 mm.
 19. The method for producing a heattransfer device of claim 17, wherein the first end of the substrate isoriented in a downward direction within the second layer mixture at atemperature of between about 55° C. and about 65° C. for at least 4hours, forming a second layer having a thickness of between about 0.008mm and about 0.012 mm.
 20. The method for producing a heat transferdevice of claim 17, wherein the temperature of the heating step whenapplying the second layer is approximately 40° C., and wherein the plugis removed from the bore for no more than approximately 2 seconds.
 21. Amethod for preparing a heat transfer medium comprising three layers,comprising the steps of: (a) preparing a first layer mixture, whereinthe first layer mixture comprises water, beryllium oxide, a metaldichromate, calcium dichromate, and boron oxide; (b) applying the firstlayer mixture to a surface of a substrate so as to form a first layer;(c) preparing a second layer mixture comprising water, cobaltous oxide,manganese sesquioxide, beryllium oxide, strontium chromate, strontiumcarbonate, cupric oxide, titanium, potassium dichromate, boron oxide,calcium dichromate, and a metal dichromate; (d) applying the secondlayer mixture to the first layer so as to form a second layer on top ofthe first layer; (e) preparing a third layer powder, wherein the thirdlayer is a powder prepared from a blend comprising one or more denaturedoxides selected from the group consisting of denatured rhodium oxide,denatured radium oxide, and combinations thereof; one or more Group IAdichromates selected from the group consisting of sodium dichromate,potassium dichromate, and combinations thereof; silver dichromate;monocrystalline silicon; beryllium oxide; strontium chromate; boronoxide; sodium peroxide; titanium; and a metal dichromate; and (f)exposing the second layer to the third layer powder so as to form athird layer on top of the second layer, thus forming the three layerheat transfer medium.
 22. A method for preparing a heat transfer mediumcomprising three layers, comprising the steps of: (a) preparing a firstlayer mixture at a temperature of between about 0° C. and about 30° C.and at a relative humidity of no greater than 40%, wherein the firstlayer mixture comprises water, beryllium oxide, a metal dichromate,calcium dichromate, and boron oxide; (b) applying the first layermixture to a surface of a substrate wherein at least a portion of thefirst layer mixture penetrates at least partially into the surface ofthe substrate so as to form a first layer; (c) preparing a second layermixture at a temperature of between about 0° C. and about 30° C. and ata relative humidity of no greater than 40%, wherein the second layermixture is prepared as an aqueous mixture comprising water, cobaltousoxide, manganese sesquioxide, beryllium oxide, strontium chromate,strontium carbonate, cupric oxide, titanium, potassium dichromate, boronoxide, calcium dichromate, and a metal dichromate; (d) applying thesecond layer mixture to the first layer so as to form a second layer ontop of the first layer; (e) preparing a third layer powder at atemperature of between about 0° C. and about 30° C. and at a relativehumidity of no greater than 40%, wherein the third layer is a powderprepared from a blend comprising one or more denatured oxides selectedfrom the group consisting of denatured rhodium oxide, denatured radiumoxide, and combinations thereof; one or more Group IA dichromatesselected from the group consisting of sodium dichromate, potassiumdichromate, and combinations thereof; silver dichromate; monocrystallinesilicon; beryllium oxide; strontium chromate; boron oxide; sodiumperoxide; titanium; and a metal dichromate; and (f) exposing the secondlayer to the third layer powder so as to form a third layer on top ofthe second layer, thus forming the three layer heat transfer medium.